2004 Volvo S80 Problems

What owners report

Owners of this model year most often describe fuel odors and fuel leaks, typically from the fuel pump, and some say the problem continued after a recall repair. Other common reports involve the engine shutting off, stalling, or losing power while driving, power steering failures or steering pull, front control arm or axle failures, and seat belts that fail to latch or retract. Recorded mileage varies widely, and many fuel complaints involve cars with more than 90,000 miles.

1. 1
   Fuel system

   Fuel odor and leaks from the fuel pump

   • 15 complaints (30%)
   • median 120,500 mi at 12.1 yrs old (12 state mileage)
   • filed 2010–2020

   Owners describe a strong gasoline smell around or inside the car, sometimes first noticed at highway speed, with fuel leaking from the top of the fuel pump or a cracked pump flange. Some say the smell became strong enough that the car could not be kept in a garage, and others mention lower fuel economy. Some owners say a related recall covered similar cars but not theirs, or that the VIN was left out of the recall. Others say the manufacturer offered a pump replacement but not the labor, or that the repair fell outside the extended warranty. Recorded mileage ranges from about 19,000 to 205,000 miles, and some complaints describe the smell growing stronger over time.

   Recall 09V483000

   What to check: Ask whether the fuel pump was replaced under the 09V483000 campaign and whether the fuel pump flange was checked. Check for fuel odor inside the cabin and in the garage, and look for wet staining on top of the fuel tank or pump area.

   2 excerpts from owner complaints in NHTSA records

   “After noticing a very acute smell of gas I took the vehicle in for inspection. The mechanic advise that I had a fuel leak in my 2004 Volvo s 80 . Thats could have been a serious problem and that the car is not driveable in this condition.”

   NHTSA complaint #11325903, filed 2020-05, 190,000 miles

   “There was a recall regrding fuel smell/fuel pump and/or fuel seal problem in 2010..my car is not regersted in the data base for the dealer to fix the fuel pump. How do I get a dealer vocher to take of this problem.”

   NHTSA complaint #10806349, filed 2015-11, 121,000 miles
2. 2
   Engine cooling

   Engine shuts off, stalls or loses power

   • 11 complaints (22%)
   • median 112,002 mi at 6.8 yrs old (9 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2023

   Owners describe the engine shutting off or cutting out while driving, sometimes without warning and sometimes repeatedly. Others describe hesitation, sputtering, or surging when accelerating or stopping, along with a reduced engine performance warning, and in some cases the electronic throttle module or throttle body was identified as the problem. Some dealers could not find a fault during inspection. Some complaints say the key or key fob turned the engine off while the car was moving, because the key or fob twisted or was bumped. Recorded mileage ranges from about 800 to 165,000 miles, and some shut-offs happened at highway speed or while coasting to a stop.

   What to check: Ask the dealer to scan for stored engine and throttle codes, and whether any electronic throttle module or throttle body service applies. Check the key and fob for looseness or twisting, and test-drive the car to confirm it keeps running and responds smoothly from a stop.

   2 excerpts from owner complaints in NHTSA records

   “While driving down the road, my 2004 Volvo S80 2.5t will suddenly lose power, surge forward or enter 'limp mode with a message of reduced engine performance followed by engine service required. Using an obdii code reader I discovered that these messages and my issue were caused by a problem within the electronic throttle module (etm). I took it into a local Volvo repair shop and they confirmed that this was a throttle body issue. …”

   NHTSA complaint #10268690, filed 2009-05, 77,415 miles

   “My wife was driving our two kids in our 2004 Volvo S80 on I-75 when the vehicle just completely stopped operating. She could not get the vehicle to the side of the interstate as when she pressed the gas pedal, the engine would not even rev up. My wife an children were stuck in the middle of the interstate in a car that wouldn't drive. The dash stated reduced engine performance . She called me on my cell in a panic as cars on I-75 were flying by her and swerving out of her lane to avoid colliding with our vehicle. …”

   NHTSA complaint #10348614, filed 2010-08, 152,000 miles
3. 3
   Steering

   Steering shake, pull or power steering failure

   • 5 complaints (10%)
   • median 85,500 mi at 5.4 yrs old (2 state mileage, few)
   • filed 2005–2023

   Owners describe power steering that activated suddenly and made the car hard to turn in a sharp turn, and power steering that failed within minutes after the car pulled to the right over a bump. A complaint says a power steering reservoir was reportedly made from the wrong plastic, which could expand, leak fluid, and possibly fail, and that repair would be the owner's responsibility. Another describes a steering wheel that began to shake at highway speed and a car that spun out; the dealer repaired a loose shield and attributed the event to something striking the car, while the owner noted the road was clear of debris. Recorded mileage ranges from about 72,000 to 99,000 miles, and the reports describing a sudden change came during turns or over bumps.

   What to check: Check the power steering fluid reservoir for leaks or cracks, and ask whether it was replaced with a corrected part. On a test drive, check for a pull to one side over bumps, changes in steering effort during a sharp turn, and any shaking through the steering wheel.

   2 excerpts from owner complaints in NHTSA records

   “The last time I had the car serviced the representative at the dealership said that there were issues with the power steering reservoir. He said that they had apparently made it of the wrong plastic and when it heats it expands and will leak fluid, possibly failing. I don't know what the result would be with the steering if this happened. He said that the item would be the owners responsibility to replace and they were not recalling or replacing them.”

   NHTSA complaint #10443495, filed 2012-01

   “I was driving on a highway within the designated 70 mile limit when the steering wheel began to shake and the car spun out of control. It swerved to the right and left and luckily there was no traffic, or a tragic accident could have occurred, since my two children were in the car. I landed in a ditch. The driving conditions were sunny and the road was clear of debris. The dealership repaired a loose grave shield, which they said was caused by something hitting the car, although the road was clear of debris at the time of the accident. …”

   NHTSA complaint #10130424, filed 2005-07
4. 4
   Suspension

   Front control arm, axle or wheel failure

   Mentioned in 4 of 47 sampled complaints

   Owners describe a front control arm that fractured or ground during driving, a front axle that disconnected in a parking lot, and a front wheel that separated and sent the car into an embankment. Some describe losing stability while turning or losing acceleration at about 45 mph. A complaint says the control arm kept fracturing after a repair, and it cites the front control arm recall, which concerns the stud and nut that secure the arm to the spindle. Recorded mileage ranges from about 20,000 to 157,000 miles, and a complaint says the car had pulled slightly to the right for days before a wheel separated.

   Recall 04V029000

   What to check: Ask whether the front control arm recall 04V029000 was completed on this vehicle, and have the control arms, ball joints, and axle boots checked for cracks, looseness, or play. Listen for grinding or clunking over bumps during a test drive, and have the front suspension inspected on a lift before buying.

   2 excerpts from owner complaints in NHTSA records

   “Based on NHTSA campaign 04v029000> the control arms are grinding as I drive the vehicle. There is a grinding noise coming from the front right passenger side. I have lost stabilization of the vehicle when in motion. This happens on city streets, highways and while turning. This is a problem that has LED to complainants and presents a danger while driving.”

   NHTSA complaint #10806403, filed 2015-11, 121,000 miles

   “Late evening on the 22nd , or early morning, of july 23rd I rented a Volvo S80 from hertz corporatio dia location and later on the morning of the 23rd drove with my family from denver to carbondale along I-70 at highway speeds. Shortly after arriving in carbondale my youngest son and I went from the house at which we were staying to the local 7/11 for a few supplies. While in the parking lot the front axel, driver''s side, disconnected from the vehicle. …”

   NHTSA complaint #10133624, filed 2005-08, 20,400 miles
5. 5
   Air bags

   Seat belts that fail to latch or retract

   Mentioned in 4 of 47 sampled complaints

   Owners describe a seat belt buckle that would not unlatch after repeated attempts, requiring the webbing to be cut to free an occupant. Other complaints describe passenger and rear belts that retracted while driving, and a seat belt warning light that came back after the buckle was replaced. A complaint describes airbags that did not deploy and seat belts that did not engage in a crash at low speed, with injuries reported. Recorded mileage ranges from about 24,800 to 175,000 miles, and some belt failures happened while the car was being driven.

   What to check: Check that every seat belt latches, retracts, and locks properly, including the rear and passenger belts, and watch for any airbag or seat belt warning light when starting the car. Ask for records of any buckle or belt assembly replacement and whether the warning returned afterward.

   2 excerpts from owner complaints in NHTSA records

   “While driving the srs light appeared on the dashboard and remained on. Consumer was able to maintain control of the vehicle, and drove it to the dealer for inspection. Mechanic informed determined that the seat belt buckle needed to be replaced, and replaced it. However, the problem recurred.”

   NHTSA complaint #10090335, filed 2004-09

   “The contact owns a 2004 Volvo S80. The contact stated that the passenger and rear seat belts retracted while driving. The passenger felt as if they were being strangled. The vehicle was taken to the dealer who stated that the seat belts were working up to standards. The manufacturer was made aware of the failure but did not offer any assistance. The vehicle was not repaired. The failure mileage was 24,800 and the current mileage was 25,000.”

   NHTSA complaint #10458531, filed 2012-05, 24,800 miles

Buying note. Used-car buyers should check for fuel odor and wet staining around the fuel pump, and test-drive the car to confirm steady engine running and normal steering. Ask whether the fuel system recall work was completed, and request service records for steering, suspension, and seat belt repairs.

Summary written with AI from a sample of 47 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.